Volumetric vs. Traditional Concrete Mixers
What type of concrete mixer truck is right for you?
In the construction industry, the choice of equipment can significantly influence the efficiency, cost, and quality of projects. Concrete mixers, essential for any sizable construction project, come in various types, but two of the main categories are volumetric concrete mixers and traditional rear/front discharge mixers. Understanding the differences between these can help industry professionals make informed decisions about which mixer best suits their needs.
What are volumetric concrete mixers?
Volumetric concrete mixers are relatively new but are rapidly gaining popularity due to their versatility and efficiency. These mixers measure and mix ingredients onsite, meaning they carry the cement, water, and aggregates separately and combine them to form concrete in precise quantities as needed. This method offers several advantages:
Fresh Concrete: It produces fresh concrete exactly when it's needed, ensuring the best quality by preventing premature curing.
Waste Reduction: It eliminates waste as the concrete is mixed to exact specifications, reducing excess.
Flexibility: It allows for adjustments in the mix design onsite, accommodating changes without requiring a new batch from a batch plant.
Traditional rear/front discharge mixers
Traditional concrete mixers, either rear or front discharge, are more common and have been used for decades. These mixers deliver concrete that has been mixed at a batch plant and may have reduced workability by the time it reaches the job site. Once mixed, the concrete’s formulation cannot be changed, which may lead to excess concrete being wasted or shortages if underestimated.
Technological advancements in volumetric mixers
Volumetric mixers represent a significant technological advancement in the concrete supply chain, offering a more flexible and efficient approach compared to traditional drum (or barrel) mixers. These innovations are enabled by developments in several key technological areas, including sensor technology, digital communication protocols, and material handling systems. Here's a deeper look at how these technologies have been pivotal in the development and effectiveness of volumetric mixers:
1. Advanced Sensor Technology
Volumetric mixers utilize sophisticated sensor systems to precisely measure and control the quantity of each ingredient added to the mix. These sensors ensure that the exact amount of cement, water, and aggregates are used, which is crucial for achieving the desired concrete quality and strength specifications. Sensors used in volumetric mixers include:
Load Cells: Integrated into the storage bins and mixing chamber, load cells provide real-time data on the weight of the materials, ensuring accurate proportions are maintained throughout the mixing process.
Moisture Sensors: Embedded within the mixer, these sensors monitor the moisture content of the aggregates and adjust the water quantity automatically to achieve the correct slump (consistency) of the concrete, which is crucial for the concrete's performance.
2. Real-Time Data Communication
The use of advanced communication protocols allows volumetric mixers to operate with greater precision and reliability. These systems enable real-time communication between the mixer's various components and the operator’s control system, often facilitated through wireless technologies.
3. Material Handling and Hydraulic Systems
The efficiency of volumetric mixers is largely dependent on their ability to handle materials precisely and reliably. Advances in hydraulic engineering have enabled these mixers to deliver materials to the mixing chamber accurately and consistently. Some examples include:
Automated Gates and Feeders: Controlled by the central digital system, these components manage the release of materials into the mixing chamber, ensuring that the mixing process is both swift and precise.
Variable Speed Mixing: Advanced hydraulic and motor systems allow for the adjustment of mixing speeds, accommodating different types of concrete mixes and applications without compromising the quality of the mix.
Customization and flexibility
Unlike traditional mixers that must return to a batch plant for each new load, volumetric mixers can produce different types of concrete on demand at the job site. This capability is underpinned by modular design principles and quick configuration systems. Operators can adjust the concrete mix in response to immediate requirements or changes in environmental conditions, such as temperature and humidity, which affect how concrete sets.
A remote control as configurable as the mixer
Volumetric mixers require precise controls, which are often digital and can be adjusted in real-time. The Aarcomm Handheld remote control system is particularly beneficial for operating these advanced volumetric mixers. It provides:
Unlimited Functionality: Operators can control multiple aspects of the mixer from a single handheld device, from the flow of materials to the speed of the mixing drum.
Sensor Feedback: Real-time data from various sensors can be fed back to the operator through the handheld device, ensuring that the concrete mix meets the specified requirements without errors.
Ideal users and applications
Given their technological capabilities and efficiency, volumetric mixers are especially suited to certain types of users and applications:
General Contractors and Subcontractors: Who require quick adjustments in concrete consistency and quantity directly at construction sites.
Military and Municipalities: Who are involved in infrastructure projects that require adherence to exacting standards and specific requirements - often in varied and challenging environments.
Ready Mix Companies: Looking to reduce waste and increase customer satisfaction by delivering precisely mixed concrete.
Making the right choice for your use case
The choice between volumetric and traditional concrete mixers depends significantly on the specific needs of the project. For those who value flexibility, efficiency, and technological integration, volumetric mixers equipped with systems like the Aarcomm Handheld remote provide a compelling option. These mixers not only offer a higher degree of control but also align with sustainable practices by reducing waste and enhancing the overall quality of the concrete delivered.
As the industry continues to evolve, the adoption of advanced technologies such as volumetric mixers is likely to increase.
